TFP Fiber Preform Production Using Elastic Base
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The TFP process for producing fiber preforms is limited by the need for a backing layer, which adds weight and restricts the realization of ideal fiber alignment and surface geometry, and requires multiple foam cores for different geometries, leading to inefficiencies in material usage and production complexity.
Innovation Solution
A method using a flexible and elastic base, such as a rubber or silicone sheet, that can be adapted to various surface geometries before and after laying fiber strands, allowing for the elimination of the backing layer and enabling the production of fiber preforms with any desired thickness and geometry, utilizing a CNC-controlled sewing machine and open-loop/closed-loop control for precise fiber alignment and surface deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a backing layer is used in the TFP process to support fiber strands during laying, then the fiber strands can be properly attached and positioned, but the overall weight of the fiber preform increases and the mechanical properties are impaired due to non-optimal fiber alignment in the backing layer
Solution Approach 1:
The invention extracts and eliminates the backing layer from the TFP process by using a self-supporting fiber strand configuration where fibers are attached directly to each other through looping and stitching, removing the unnecessary weight and improving mechanical properties while maintaining attachment stability
Solution Approach 2:
The invention merges the functions of the backing layer and fiber strands by integrating the support function directly into the fiber strand structure itself, where the fiber strands form both the structural element and the supporting matrix through interconnected looping patterns
2Ease of manufacture
If a backing layer is used to support fiber strands during the TFP process, then fiber placement can be maintained, but the fiber alignment deviates from the optimal flux of force direction reducing mechanical efficiency
Solution Approach 1:
The invention removes the backing layer that causes alignment deviations and instead implements a direct fiber-to-fiber attachment system where strands are looped and stitched together, enabling optimal alignment with the flux of force while maintaining manufacturing feasibility
Solution Approach 2:
The invention applies different attachment patterns and fiber orientations in different regions of the fiber preform to match the local flux of force requirements, optimizing strength where needed while maintaining ease of manufacture through standardized stitching processes
3Adaptability or versatility
If multiple foam cores are used to support different surface geometries in the TFP process, then various fiber preform shapes can be produced, but the device complexity and production costs increase
Solution Approach 1:
The invention creates a universal attachment system using standardized looping and stitching techniques that can accommodate any surface geometry without requiring specific foam cores, making the process adaptable to various shapes while reducing device complexity and inventory requirements
Solution Approach 2:
The invention introduces dynamic adaptability by using flexible fiber strands that can be looped and stitched to conform to any surface geometry on demand, eliminating the need for static foam core inventories and reducing production complexity
4Loss of substance
If the backing layer is removed to reduce weight, then the fiber preform weight and material usage decrease, but the fiber strands become difficult to support during the laying process
Solution Approach 1:
The invention combines the support function with the fiber strands themselves by creating an interconnected network where strands are looped and stitched together, eliminating the need for a separate backing layer while maintaining ease of manufacture through self-supporting structures
Solution Approach 2:
The invention uses the fixing thread and looping mechanism as an intermediary that provides temporary support during the laying process, allowing strands to be handled and positioned easily without a permanent backing layer, then removed or integrated into the final structure
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method allows for the production of fiber preforms with optimal fiber alignment and complex geometries on a universal base, reducing material waste, weight, and production costs, while maintaining mechanical integrity and enabling the creation of composite components with enhanced strength and reduced weight.
Implementation Method 1
a flexible and elastic base, such as a rubber or silicone sheet, that can be adapted to various surface geometries
Data Source
AI summary
Disclosed is a method for producing single- or multi-layered fiber preforms by the TFP process with fiber strands which are aligned in particular such that they are oriented with the flux of force, wherein the fiber preforms have virtually any desired material thickness without troublesome backing layers and have virtually any desired surface geometry, comprising the steps of: laying and attaching the fiber strands on a flexible and elastic base, in particular a base formed by an elastomer, with a fixing thread led through a sewing head to form the fiber perform; and lifting the fiber preform off the elastic and flexible base. The fiber preforms produced by means of this method have a virtually optimum fiber alignment, that is to say substantially oriented with the flux of force, and no appreciable flaws in the arrangement of fibers, and consequently make it possible to create composite components that can withstand extreme mechanical stress and are at the same time lightweight, for example by subsequent processing in the RTM process.